Finite element analysis regarding the forming behaviour of symmetric hybrid structures consisting of two sheet metal outer layers and a thermoplastic core

Abstract

To face challenges like damping effects or weight reduction in the automotive sector, new hybrid material combinations are developed. One possibility is the combination of several symmetric material layers with varying material characteristics to achieve in the component production less weight and appropriate stiffness in comparison to components produced with sheet metal. This article deals with the characterization of deep drawing behaviour of layered sandwich structures. The behaviour of the several layers and the layer interaction have been taken into account for the technical design of a deep drawing process. A material layer characterization is performed. Instabilities as interlaminar failures, ruptures or wrinkling of the structure have been investigated as part of additional experimental characterization tests on the basis of various deep drawing process parameters. Finally, the experimental data is used as input for the numerical modelling and simulation of layered structures. The FE simulation includes the material behaviour of the layers and layer interactions with cohesive zone modelling. Based on the results an important contribution for prediction accuracy in the numerical simulation has been provided.